Molded pulp egg carton



March 27, 1956 J w cox 2,739,750

MOLDED PULP EGG CARTON Filed Jan. 29, 1952 2 Sheets-Sheet l @mmmm AHA" HVVENTOR.

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March 27, 1956 J w, cox 2,739,750

MOLDED PULP EGG CARTON Filed Jan. 29, 1952 2 Sheets-Sheet 2 i x w 27 -QK 1 IN V EN TOR.

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MOLDED PULP EGG CARTON John W. Cox, Chicago, 111., assignor, by mesne assignments, to The Diamond Match Company, New York, N. Y., a corporation of Delaware Application January 29, 1952, Serial No. 268,758

6 Claims. (Cl. 229-25) The present invention relates to an improved cellular molded pulp egg carton, particularly a so-called 2 x 6 style carton in which the cells are arranged in two rows of six each, which carton has great strength, rigidity and resistance to crushing yet is of maximum possible compactness, thus specially adapting filled 2 x 6 type cartons to be packed in standard, thirty-dozen capacity egg cases or creates.

The invention generally relates to a very compact molded pulp carton having three hingedly articulated sections, includin a cellular bottom section, a cellular inner cover section and a non-cellular, tray-like outer cover section, the inner cover section being characterized by an improved cell structure adapted to encase the upper portion of eggs disposed in cells of the bottom section without compressing the same noticeably, this eifect being occasioned by the fact that a hole is formed, or equivalent provision made, in the material of each cell of the inner cover section which otherwise would engage the egg for the purpose of avoiding direct and severe pressure in this zone.

It is a general object of the invention to provide an integrally hinged, three section carton of molded pulp, preferably of the 2 x 6 style, which is of minimum transverse, longitudinal and vertical dimension, yet which affords full protection for the largest sizes of eggs.

Yet another object is to provide a hinged, three-section, molded pulp egg carton featuring a cellular inner cover section of the type described above and a non-cellular outer cover section adapted to be snugly nested over the inner cover section when the carton is in closed condition, the inner cover section being reduced to a minimum side-by-side width by partially exposing the interior of the egg receiving cells in one or both of the rows extending along the sides of the inner cover section, thereby enabling the largest sizes of eggs to be accommodated while still preserving a snugly nested interfit of the inner cover section within the outer cover section, avoiding objectionably compressing the eggs when the carton is tightly closed.

A still further object is to provide a three-section, hinged molded pulp carton as described above, in which the coacting cellular bottom and inner cover sections immediately encasing the eggs are provided with a number of coacting abutment areas in direct vertical engagement with one another to brace these sections in their closed condition, and in which the outer cover section, in nesting snugly over the inner cover section, prevents relative lateral or longitudinal shift of the first named sections and thus insures the proper and intended vertical engagement of their abutment areas.

A still further object of the invention is to provide a three-section carton of the general type described, in which an inner cover section is attached to the front edge of a bottom section along and by means of a series of abutment areas or platforms which are spaced apart adjacent the center of certain egg cells of the sections,

nited States Patent thereby aifording a novel and improved hinged connection.

The foregoing statements are indicative in a general way of the nature of the invention. Other and more specific objects will be apparent to those skilled in the art upon a full understanding of the construction and operation of the improved carton. A single embodiment of the invention is presented herein for purpose of illustration, though the invention may be incorporated in other modified forms coming equally within the scope of the appended claims.

In the drawings,

Fig. 1 is a top plan view of a 2 x 6 style molded pulp carton embodying the invention, the carton being illustrated in the flat, open condition of its three sections;

Fig. 2 is a front elevation of the carton of Fig. 1, being considered as viewed from the lower edge of Fig. 1;

Fig. 3 is a view in transverse vertical section along line 33 of Fig. 1, indicating certain structural details of the carton, particularly of the cellular bottom and inner cover sections thereof;

Fig. 4 is a somewhat enlarged fragmentary view in transverse section along a line corresponding to line 4--4 of Fig. 2, further illustrating specific structural details of the inner cover section of the carton;

Fig. 5 is a top plan view showing the carton in partially closed relation with its inner cover section swung into covering relation to the cellular bottom section; and

Fig. 6 is a view in transverse section through the closed and locked carton, being sectioned in part corresponding to Fig. 3 and in part broken away and sectioned corresponding to Fig. 4.

The present improvements lend themselves to a 2 x 6 style pulp carton, in which a dozen eggs are disposed in two parallel rows of six cells each, in view of the fact that one of the main objects is to minimize the over-all transverse dimension of the carton and thus suit the same for packing in a standard thirty-dozen capacity bulk egg case, just as 2 x 6 size paperboard cartons are presently packed. However, individual features of the invention are not limited in application to the 2 x 6 style, but are equally well adapted for incorporation in the equally or better known 3 x 4 style carton.

The carton chosen for illustration comprises three sections of similar, elongated rectangular outline, namely a cellular bottom section 10, a cellular inner cover section 11 integrally hinged to a side margin of section 10 by a crease 12 formed during the molding operation, and a non-cellular, tray-like outer cover section 13 which is integrally hinged by a crease 14 to the opposite side margin of bottom section 10. In manipulating the carton to closed condition the sections 11, 13 are successively swinagle, in that order, about creases 12, 14 respectively.

Bottom section 10 is molded to provide a central upstanding abutment or post 15 of quadrilateral outline as viewed in plan, this post being disposed medially of the opposed sides and ends of the section. It is coextensive in height with the outer walls of the section 10, as appears in Figs. 3 and 6. Other generally similar separator posts 16, differing from abutment 15 in that they are of slightly less height and are open at the top, thus providing ventilating apertures 17, are disposed in longitudinal alignment with the central abutment. The separators and abutment are integrally connected in the longitudinal direction by longitudinal partition elements 18 of inverted V-shape outline, constituting a longitudinal partition or divider formation which extends from endto-end of the carton. The endmost partition elements 18 merge with triangular abutment webs 19 which are coplanar with the top of cellular section 10. Similar transverse partition elements 20 extend transversely from the local crushing stress.

ensures respective separator elements 15, 16 and likewise merge outwardly with triangular abutment webs 21 which are formed along opposite side margins of the bottom section 10. These webs are also approximately coplanar with the top of section 10.

As illustrated in Figs. 2 and 6, one pair of the transverse divider or partition elements 20, namely those which extend from apcrtured separators 16 toward the hinge 12 or the inner cover section 11, merge with specially molded locking areas 22 adjacent that hinge. At these zones bottom section it) is molded to provide a downwardly stepped shoulder 23 which extends horizontally outwardly from the transverse partition element 20 to a point short of the side margin of the section. An opening 24 is formed in this shoulder portion, as by the application of a suitable plug to the suction molding dies, preventing the deposition of fibers of the watery pulp molding slurry in these areas. At the same time a substantial and increased mass of paper pulp stock is deposited between the sides of the plug and adjacent surfaces of the die surrounding the same, with the result that openings 24 are bounded by wall surfaces of substantial transverse thickness, for a purpose to be described.

Inner cover section 11 is of less height than the bottom section, as appears in Figs. 2 and 3. It is molded to provide a succession of vertically disposed separator posts 26 along its longitudinal center line, arranged in transverse alignment with the separator and abutment .posts 15, 16. Posts 26 are integrally connected by longitudinal partition elements 27 of inverted V-outline, and similar transverse partition elements 28 merge therewith, in the manner described in connection with the separator elements of bottom section it). The longitudinal and transverse partition elements and posts referred to merge at the ends and sides of the section into the abutment web areas 29 which are coplanar with the top of posts '26. These abutment areas are adapted to take vertical bracing engagement with the webs 19 and 21 of the bottom section when the carton is closed. The center separator 26 similarly abuts the center post 15 of section to afford required support for the covers 11, 13 in this area.

Referring to Fig. 4, the bottoms of the cells of the inner cover section 11, which are inverted over the eggs when the carton is closed, are each molded to provide a hole 30, so that when the carton is closed the upper surface of the eggs E is accommodated Without imposition of Yet the surrounding portion of the cell top gives rigid vertical strut action to prevent collapse of the cell and to support outer cover section 13. If desired, the same effect may be obtained in some degree by the provision of a wafer-like center area at this zone which is of substantially reduced thickness as compared to the remainder of the cell wall structure. Small round egg cushioning formations 39' are preferably molded at the. bottom of each cell of the bot-tom section 10.

It should also be noted by reference to Figs. 1, 3 and 6 that the cells of the inner cover section are substantially larger in size than those of the bottom section, though on the same centers, so as to afford adequate room for the larger upper halves of the eggs. This would ordinarily introduce a problem in closing the outer cover over the inner cover due to decreased side clearance between the two sections. To overcome the problem the longitudinal sides of the inner cover section 11 are molded in a'manner to laterally expose the cells thereof which extend along and adjacent the same. Here again, the molding die is blocked out so that pulp is not deposited in these zones, leaving a U-shaped opening 31 at:each cell along the respective sides of section 11. Hence section ll'still accommodates eggs of large girth but removal of material at the cell sides permits ready closure of the outer cover without undue binding. The objective of providing a carton of minimum over-all width, capable of being packed in a thirty dozen egg case, and of packaging the largest sizes of eggs without danger of breakage (see Fig. 6), is thus furthered.

it will be noted in Fig. 1 that the apertures 31 in the cells adjoining cover crease 12 are even carried across that crease and into the material of bottom section 10, with the effect of leaving the two sections hinged to gether.

Outer cover section 13 is defined by a flat top panel 33 and integral inclined side and end walls 34, 35, respectively, which are integrally connected to one another by rounded corners. The cover section, like the two other sections, is fiangless in character, i. e., they all lack the horizontal, outwardly projecting shoulder or flange about the perimeter thereof which is characteristic of many molded pulp egg cartons. This is in the interest of preserving a minimum over-all dimension for case packing. The flanges prevent case packing, hence have been omitted.

Locking tabs 37 are integrally formed on the free side margin of cover section 13, being in transverse align ment with the tab receiving openings 24 of bottom section 10. The tabs have a widened outer extremity 38,

a reduced width neck 39, and an outwardly flared inner shoulder 40 joining the same to the margin of the cover section wall. Tabs are uncreased in this connecting zone for additional strength and resistance to tear upon iiexure. The lateral dimension of the extremity 33 of the tab is somewhat in excess of the width of the openings 24, so that the tabs are flexed rearwardly somewhat in being wedged past the side walls of the openings to lock behind the inner edge of the opening, in a fashion illustrated in Fig. 6.

The carton is shown in closed condition in Fig. 6. The eggs are inserted in the cells of bottom section 10, large end up, the inner cover section 11 is swung about hinge 12 into closing relation to section it and cover section 13 is then swung about hinge 14 into snugly nested relationship over the inner cover section, as shown in Fig. 6. The central post 15 of the bottom section is vertically abutted and sustained by the aligned post 26 of section 11. The various boundary webs 2.9, 19 and 21 have similar engagement, thus to atiord ample vertical bracing of the two sections. The cover 13 restrains any tendency of the sections 10, 11 to shit-t transversely or endwi'se relative to one another, which is the primary cause of carton telescoping and collapse in existing structures. The locking tabs 37 have an important function in holding the outer cover down in snugly nested, .restraining relation to the inner cover, with its panel 33 in direct engagement with the top of the inner cover.

In this condition the carton is rigid and block-like. The eggs are well protected against damage due to impact. Those disposed in the outer row or bottom section cells, and exposed laterally through inner cover cell openings 31, are nevertheless properly shielded by the adjacent walls 34 of the integrally hinged cover section 13. They are well pocketed in the relatively deep cells of bottom section 13, which receive the smaller girth egg portion. The bottom section cells accordingly may taper more sharply toward the vertical and still receive and support the eggs properly, in the lateral sense, without undue side compression.

By the'same token, the cells of inner cover section 11 can be made larger than in existing cartons, for greater egg space. As stated, provision of the cell side openings 31 presents augmented egg space. Though the presence of the openings adjacent the bottom-inner cover hinge 12 has'some'tei ide'ncy to Weaken the hinging strength at this point, this is unimportant because the inner cover is well braced laterally by the outercover, as explained above. More important, and completely offsetting the :.tendency referredto two thicknesses of stock at a critical zone arceliminated; and the sections hinge more flexibly and readily due to their longitudinally spaced hinge creases at abutments 21, 29.

The hole 30 or, alternatively, a thin wafer section in the inner cover section 11 which overlies the eggs receives, or affords a soft, yielding cushion for, an extra large egg, eliminating the possibility of smashing the same due to unyieldability at this area. At the same time the outer cover protects against local impact at a cell area and the two covers have ample rigidity to resist crushing under direct vertical load, bending stress or flexure.

I claim:

1. A molded pulp egg carton comprising a bottom section subdivided into rows of cells of predetermined vertical depth, an inner cover section integrally hinged at one margin to a margin of said bottom section and subdivided into rows of cells of vertical dimension less than said cover section cells, one of which rows extends adjacent the inner cover section hinge, and a non-cellular outer cover section integrally hinged to another margin of said bottom section, said inner cover section being formed with apertures which open laterally to and expose an outer side portion of the cells of an outer row when said inner cover section is swung to closed relation to said bottom section, the area of each of said apertures comprising a major portion of the area of its associated cell wall, said outer cover section being swingable to snug nested relation over said inner cover section to position a wall thereof in immediate covering relation to said apertures and laterally shield the exposed portions of the cells of said outer row.

2. A molded pulp egg carton comprising a bottom section subdivided into two rows of cells, an inner cover section integrally hinged at one margin to a margin of said bottom section and subdivided into two rows of cells, one of which rows extends adjacent the inner cover section hinge, said respective sections being provided with transversely aligned abutment areas adjacent the hinge thereof and between successive cells of the respective J rows, which abutment areas are engageable with one another in the closed condition of the carton to vertically brace the latter, and an outer cover section integrally hinged to another margin of said bottom section, said inner cover section being formed with openings between the abutment areas in each of the cell walls, the area of each of said openings comprising a major portion of the area of its associated cell wall and extending to and interrupting said bottom cover section hinge, thereby leaving said sections hinged to one another primarily at the abutments adjacent said hinge, thereby to laterally expose a side portion of eggs in the cells of a row thereof adjoining its hinge to said bottom section when said inner cover section is swung to closed relation to the latter, said outer cover section being swingable to nested and closed position over said inner cover section, with said outer cover section in immediate side closing relation to said exposed cell side portions.

3. A molded pulp egg carton comprising a bottom section subdivided into rows of cells of predetermined vertical depth, an inner cover section integrally hinged at one margin to a margin of said bottom section and subdivided into two rows of cells, the material of said inner cover section which horizontally defines the cells thereof having egg receiving areas formed therein, and a non-cellular outer cover section integrally hinged to another margin of said bottom section, said inner cover section having the outer side walls of the cells therein formed with apertures opening laterally into said cells and exposing a side portion of eggs in the cells of both rows when said inner cover section is swung to closed relation to said bottom section, said apertures being of an area which comprises a major portion of the area of the associated cell wall, said outer cover section being swingable into nested relation over said inner cover section, in which the walls of said outer cover section are positioned in immediate covering relation to said apertures and the exposed portions of the cells of said rows are laterally shielded thereby.

4. A molded pulp egg carton comprising a tray-like bottom section subdivided by longitudinal and transverse abutment and divider formations into rows of cells, an inner cover section of tray-like form integrally hinged to a margin of said bottom section, said inner cover section being subdivided by longitudinal and transverse abutment and divider formations into rows of cells, certain portions of said formations of said respective sections being engageable with one another in the closed condition of the carton to vertically brace the latter, and an outer cover section of tray-like form integrally hinged to the opposite margin of said bottom section, said inner cover section having openings of substantial area in the outer side walls of the cells of the outer rows which extend vertically a substantial distance from the bottom side edges thereof when said inner cover is in closed relation to said bottom section to laterally expose a side portion of the cells of said outer rows, said outer cover section being swingable to snug nested and closed relation over said inner cover section in which the side walls of said outer cover section are positioned in immediate side closing relation to said exposed cell side portions.

5. A molded pulp egg carton comprising a bottom section subdivided into rows of cells, an inner cover section integrally hinged at one margin to a margin of said bottom section and subdivided into rows of cells, one of which rows extends adjacent the inner cover-bottom section hinge, and a non-cellular outer cover section integrally hinged to another margin of said bottom section, said inner cover section having apertures in the outer side wall thereof which open laterally into the cells of the row of cells adjacent the inner cover-bottom section hinge, the area of each of said apertures comprising a major portion of the area of its associated cell wall, said apertures exposing side portions of eggs in the cells when said inner cover section is swung to closed relation to said bottom section, said outer cover section being swingable.

to snug nested relation over said inner cover section, in which the side wall of said outer cover section is in immediate covering relation to said apertured cell walls and exposed portions of eggs in the cells thereof are laterally shielded by portions of the wall of said outer c0ver'section.

6. A carton as recited in claim 5 and said inner cover section having the apertures in the side wall thereof extending through said inner cover-bottom section hinge.

References Cited in the file of this patent UNITED STATES PATENTS 1,323,074 Lesem Nov. 25, 1919 1,963,379 Petter June 19, 1934 2,529,140 Cox Nov. 7, 1950 2,569,681 Lennon Oct. 2, 1951 2,600,130 Schilling June 10, 1952 

